Floating layer formation, foaming, and microbial community structure change in full-scale biogas plant due to disruption of mixing and substrate overloading

Background: The use of biogas as renewable resource of energy is of growing interest. To increase the efficiency and sustainability of anaerobic biogas reactors, process failures such as overacidification, foaming, and floating layers need to be investigated to develop sufficient countermeasures and early warning systems to prevent failure. Methods: Chemical, rheological, and molecular biological analyses were conducted to investigate a stirring disruption in a full-scale biogas plant. Results: After the agitation system was disturbed, foaming and floating layer formation appeared in a full-scale biogas plant fed with liquid manure and biogenic waste. Rheological characterizations and computational fluid dynamics (CFD) revealed a breakdown of the circulation within the reactor and a large stagnation zone in the upper reactor volume. Molecular biological analyses of the microbial community composition in the floating layer showed no differences to the digestate. However, the microbial community in the digestates changed significantly due to the stirring disturbances. Foam formation turned out to be a consequence of overloading due to excessive substrate supply and disturbed mixing. The subsequent increase in concentration of both acetic and propionic acids was accompanied by foaming. Conclusions: Effective mixing in full-scale biogas plants is crucial to avoid foaming and floating layers and to enhance sustainability. Disturbed mixing leads to process imbalances and significant changes in the microbial community structure. Additionally, controlled feeding might help prevent foam formation due to overloading.